Refractory anchor device and system

ABSTRACT

Refractory anchoring devices include a main body and a mounting feature for mounting to a thermal vessel. The main body has the shape of two end-to-end Y&#39;s forming a central segment, two branch segments extending from each end of the central segment, and an extension segment extending from each of the four branch segments, to collectively form four unenclosed cell openings that are each semi-hexagonal in shape. Some embodiments include four reinforcement segments with each one extending into a respective cell opening, four voids with each one extending through respective adjacent branch and extension segments, an underbody gap formed under the central segment for refractory interlinking between cell openings, and/or a single stud-welding stud for the mounting feature. Refractory anchoring systems and methods include an array of the refractory anchoring devices arranged and mounted so that the unenclosed semi-hexagonal cell openings of adjacent anchoring devices cooperatively form substantially hexagonal cells.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. Non-Provisional patentapplication Ser. No. 16/526,564 filed Jul. 30, 2019, which claims thepriority benefit of U.S. Provisional Patent Application Ser. No.62/715,894 filed Aug. 8, 2018, which are hereby incorporated herein byreference.

TECHNICAL FIELD

The present invention relates generally to the field of refractorylinings for high-temperature vessels used in industrial and chemicalprocesses, and more particularly to anchor systems for holdingrefractory materials in place in high-temperature and abrasiveenvironments.

BACKGROUND

Thermal-process vessels used in oil refineries and other petrochemicaland chemical process facilities have highly abrasive andhigh-temperature environments. To protect the vessel shells (e.g.,sidewalls), their internal surface is typically lined with a refractorymaterial such as a thin layer of concrete. To secure the refractorymaterial in place, anchoring devices and systems have been developed.

The most common form of thin-layer abrasion-resistant refractoryconcrete anchoring system is called HEXMESH (aka “hexmetal” or just“hex”) anchor sheets. Hex includes a series of steel strips that areinterlocked (i.e., “clinched” together by a tab-and-slot arrangement) toform a sheet or mat of hexagonal cells in a honeycomb-patterned array orgrid. The hex sheets are installed by fitting (bending/shaping andcutting/sizing) them to whatever vessel shape and size is to be lined,and then welding them in place by a large number of welds to create astrong attachment to the underlying vessel shell. Once welded, mixedrefractory concrete is then rammed, beaten, or packed into the hexcells. The refractory concrete and hex sheet together form a barriersystem that protects the underlying vessel shell from heat, abrasion,and chemical attack.

Over the decades that hex has been in use, several weaknesses in thissystem have been exposed. The hex and refractory system must move inconcert with any flex that occurs in the vessel shell because the hexsheet is fitted and welded flush with and rigidly to the vessel shell.This makes the hex and refractory system prone to “biscuiting,” whichmeans individual hex cells will tend to “pop” the refractory concreteout in a hexagonal biscuit shape when the vessel shell experiencesthermal expansion or contraction. In addition, this can compromise theprotective capabilities of the refractory concrete liner by opening gapsthat allow catalysts, gases, carbon, and other process-related materialsto contact the exposed portion of the vessel shell. This in turn canlead to further failure of the refractory concrete liner system and theneed for premature replacement of extremely expensive process vesselsand components. Furthermore, installing hex is very time-consuming,tedious, and cumbersome because of the large number of welds requiredand because the sheets must be cut on-site to custom-fit each vessel,beat into shape and place with a hammer, and sometimes cut into smallpieces to fit through access openings to the work areas, with this beingparticularly an issue for irregularly shaped vessels.

Other refractory anchoring devices and systems include D-BAR anchors(e.g., U.S. Pat. No. 6,393,789), C-BAR anchors, and G3 anchors. Some ofthese are provided in sheet form and thus must by bent and cut to fitthe individual vessel in the same manner as the HEXMESH sheets. And someof these include multiple parts that are interlocked together with aclinching system in the same manner as the HEXMESH sheets. As such,these other refractory anchoring devices and systems include some or allof the same drawbacks.

Accordingly, it can be seen that needs exist for improvements inanchoring devices, systems, and methods for refractory liners forthermal vessels. It is to the provision of solutions to these and otherproblems that the present invention is primarily directed.

SUMMARY

Generally described, the present invention relates to refractoryanchoring devices having unenclosed semi-hexagonal cell openings. Therefractory anchoring devices each include a main body and a mountingfeature for mounting to a thermal vessel. The main body has the shape oftwo end-to-end Y's forming a central segment, two branch segmentsextending at an obtuse angle from each of the two ends of the centralsegment, and an extension segment extending at an obtuse angle from eachof the four branch segments, to collectively form four unenclosed cellopenings that are each semi-hexagonal in shape. Some embodiments includefour reinforcement segments with each one extending into a respectivecell opening, four voids with each one extending through respectiveadjacent branch and extension segments, an underbody gap formed underthe central segment for refractory interlinking between cell openings,and/or a single stud-welding cylinder for the mounting feature.

Another aspect of the invention relates to refractory anchoring systemsthat include an array of refractory anchoring devices having unenclosedsemi-hexagonal cell openings. The refractory anchoring devices arearranged in the refractory anchoring systems so that the unenclosedsemi-hexagonal cell openings of adjacent ones of the anchoring devicescooperate to form substantially hexagonal cells and provide flowpassageways for the refractory to interconnect the cells.

And another aspect of the invention relates to refractory lining methodsthat use an array of refractory anchoring devices having unenclosedsemi-hexagonal cell openings. The method includes mounting therefractory anchoring devices in an arrangement to form refractoryanchoring systems with the unenclosed semi-hexagonal cell openings ofadjacent ones of the anchoring devices cooperating to form substantiallyhexagonal cells and provide flow passageways for the refractory tointerconnect the cells. In some embodiments, the refractory anchoringdevices include a single stud-welding stud for a mounting feature andthe mounting process includes stud-welding the anchor devices in place(for example using BRANDTECH precision welding equipment and processes).

These and other aspects, features, and advantages of the invention willbe understood with reference to the drawing figures and detaileddescription herein, and will be realized by means of the variouselements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following brief description of the drawings anddetailed description of example embodiments are explanatory of exampleembodiments of the invention, and are not restrictive of the invention,as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a refractory anchor according to a firstexample embodiment of the invention.

FIG. 2 is another perspective view of the refractory anchor of FIG. 1.

FIG. 3 is a top view of the refractory anchor of FIG. 1.

FIG. 4 is a bottom view of the refractory anchor of FIG. 1.

FIG. 5 is a side view of the refractory anchor of FIG. 1.

FIG. 5A shows the refractory anchor of FIG. 5 with a welding stud shownin cross section.

FIG. 6 is an end view of the refractory anchor of FIG. 1.

FIG. 7 is a perspective view of a refractory anchor according to asecond example embodiment of the invention.

FIG. 8 is another perspective view of the refractory anchor of FIG. 7.

FIG. 9 is another perspective view of the refractory anchor of FIG. 7.

FIG. 10 is a top view of the refractory anchor of FIG. 7.

FIG. 11 is an end view of the refractory anchor of FIG. 10.

FIG. 12 is a side view of the refractory anchor of FIG. 10.

FIG. 13 is a top view of a first anchoring system of the refractoryanchors of FIG. 1.

FIG. 13A is a perspective view of the first anchoring system of FIG. 13showing the installed refractory, with portions removed to reveal theunderlying anchors, forming generally hexagonal, interlinked cells.

FIG. 14 is a top view of a second anchoring system of the refractoryanchors of FIG. 1 and the refractory anchors of FIG. 7.

FIG. 15 is a top view of a third anchoring system of the anchors of FIG.1 and modified/alternative refractory anchors according to a thirdexample embodiment.

FIG. 16 is a top view of a fourth anchoring system ofmodified/alternative refractory anchors according to a fourth exampleembodiment.

FIG. 17 is a top view of a fifth anchoring system ofmodified/alternative refractory anchors according to a fifth exampleembodiment.

FIG. 18 is a perspective view of a portion of a refractory anchoraccording to a sixth example embodiment.

FIG. 19 is a top view of the refractory anchor portion of FIG. 18.

FIG. 20 is a perspective view of a portion of a refractory anchoraccording to a seventh example embodiment.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Generally described, the present invention relates to an anchoringdevice, system, and method for a refractory material for togetherforming a protective barrier system for a thermal vessel. The anchoringdevice, system, and method can be used for protecting thermal vesselssuch as high-temperature cyclone separators (e.g., fluid catalyticcrackers aka FCCs), burners, furnaces, columns, and tanks, piping forthese, and other high-temperature industrial-process containers. Thesethermal vessels operate at high temperatures of typically about 250 C toabout 1800 C. The anchoring device, system, and method can be used forprotecting such thermal vessels in oil refineries, otherpetrochemical-process facilities, chemical-process facilities,chemical-manufacturing plants, cement plants, fertilizer plants, steelmills, pulp-and-paper plants, power-generating plants, and otherfacilities and industries using such high-temperature vessels. And theanchoring device, system, and method can be used for anchoringrefractory materials including concrete, fibers, plastics, ceramics,and/or other conventional refractories, typically applied in a viscousstate and cured on site, but in some embodiments precast or otherwisepre-formed.

Referring to the drawings, FIGS. 1-6 show a thin-layerabrasion-resistant refractory anchoring device 10 according to a firstexample embodiment of the invention. The anchor 10 includes a main body12 having the shape of two “Y”s arranged end-to-end (and therebydefining two side/central semi-hexagonal (trapezoidal) openings and twoend triangular openings) and a mounting element or feature 14 formounting the main body 12 to the thermal vessel (not shown) to beprotected.

The main body 12 includes a central segment 16 (i.e., the aligned andcontinuous base legs of the two end-to-end “Y”s) and four branchsegments 18 extending from the central segment 14 (i.e., the two pairsof splayed upper legs of the two end-to-end “Y”s) with a first pair ofthe branch segments 18 extending from a first part of the centralsegment 14 and with a second opposite pair of the branch segments 18extending from a second part of the central segment 14 that is spacedapart from the first part. In the depicted embodiment, for example, thetwo branch segment pairs 18 extend from opposite outer end portions 20of the central segment 16. In some embodiments, the branch segmentsextend from the central segment before its end edges (with the centralsegment extending into the end openings) or are otherwise configured.

The four branch segments 18 are each angled with respect to the centralsegment 14 at an obtuse angle to form four unenclosed cell openings(e.g., notches or recesses) 22 between them. In the depicted embodiment,for example, each of the four branch segments 18 is arranged at anobtuse angle α of about 120 degrees from the central segment 14 in asubstantially symmetrical configuration, which leaves an obtuse angle βof about 120 degrees between the two branch segments 18 at each endportion 20 of the central segment 14. In other embodiments, the branchsegments extend from the central segment all at the same larger orsmaller obtuse angle, at two to four different angles from each other,or in another configuration.

In addition, the main body 12 of typical embodiments further includesone or more extension segments 24 extending from one or more of thebranch segments 18. In the depicted embodiment, for example, the mainbody 12 includes four extension segments 24 with each one extending froma respective one of the four branch segments 18. Typically, theextension segments 24 extend from outer end portions 26 of therespective branch segments 18. In some embodiments, the extensionsegments extend from the branch segments before their end edges (withthe branch segments extending beyond where the extension segments extendfrom) or are otherwise configured. And in some embodiments, the mainbody does not include any extension segments.

The four extension segments 24 are each angled relative to theirrespective branch segments 18 at an obtuse angle to define portions ofthe two opposite end openings 22. In the depicted embodiment, forexample, each of the four extension segments 24 is arranged at an obtuseangle θ of about 120 degrees from the respective branch segment 18 in asubstantially symmetrical configuration, leaving the extension segments24 substantially parallel with the central segment 16. As such, eachpair of the branch segments 18 and the central segment 16 aresymmetrically arranged, with each one of these three segments at 120degrees from the other two of these three segments. In otherembodiments, the extension segments extend from the branch segments allat the same larger or smaller obtuse angle, at two to four differentangles from each other, or in another configuration.

In this substantially symmetrical configuration, with the branchsegments 18 extending from the central segment 16 and the extensionsegments 24 extending from the branch segments 18 all at substantiallythe same obtuse angle, all four of the openings 22 are semi-hexagonal(the extension segments making the triangular end openings intosemi-hexagonal openings). In the depicted embodiment, for example, thetwo opposite end semi-hexagonal openings 22 are formed by one end pairof the branch segments 18 (defining two adjacent full-length sides of ahexagon) and by one end pair of the extension segments 24 (defining twoopposite/facing half-length sides of a hexagon), as shown in FIGS. 3 and6. And the two opposite central semi-hexagonal openings 22 are formed bythe central segment 16 (defining one full-length side of a hexagon) andtwo of the branch segments 18 (one of each end pair; each one definingone full-length side of a hexagon), as shown in FIGS. 3 and 5. Thus, theend semi-hexagonal openings 22 and the central semi-hexagonal openings22 are rotationally shifted by about 60 degrees with respect to eachother so that they are arranged together in a tessellated fashion.

To provide further symmetry in the configuration of the anchor 10, eachof the branch segments 18 typically has a length that is substantiallythe same as that of the central segment 16 (with all of the branchsegments 18 having the same length), and each of the extension segments24 typically has a length that is about half (or less than about half)that of the central and branch segments 16 and 18 (with all of theextension segments 24 having the same length). In this way, each of theunenclosed cell openings 22 defines a regular (equilateral)semi-hexagonal shape of the same size/area, so that a number of theanchors 10 can be arranged together with any one of the fourcells/openings 22 of one anchor cooperating with any one of the fourcells/openings of an adjacent anchor to form a substantially hexagonalcell, thereby reducing the likelihood of biscuiting. In typicalembodiments, for example, the length of the central and branch segments16 and 18 (and twice the length of the extension segments 24) is about20 mm to about 30 mm (e.g., about 25 mm), with the openings 22 thusbeing about 50 mm to about 60 mm (e.g., about 55 mm) across (e.g.,between the extension segments 24 of each end pair).

In other embodiments, the central, branch, and/or extension segments allhave a longer or shorter length, have different lengths from each other,or are provided with other lengths as may be desired. For example, insome embodiments the extension segments are shorter than one-half thelength of the central and/or branch segments, so that two anchoringdevices can be arranged end-to-end adjacently but spaced apart in ananchoring system (in the manner shown in FIG. 13, except with shorterextension segments), and the adjacent end openings of the two anchorscooperate to form a regular hexagonal cell (though not fully enclosedbecause of the end-to-end spacing between the anchors), for example asshown in FIG. 15. And in other embodiments, only one of the branchsegments at each end has an extension segment extending from it (sothere are two extension segments, one at each end of the anchor), sothat two anchoring devices can be arranged side-to-side immediatelyadjacently (e.g., with nominal spacing sufficient to avoid contactingduring thermal expansion and contraction during use) in an anchoringsystem (in the manner shown in FIG. 13, except with no side-to-sidespacing), with each extension segment positioned at a branch segment ofthe adjacent anchor without an extension segment (to fill the positionwhere an extension segment was not included in that anchor), and theadjacent central/side openings of the two anchors cooperate to form aregular hexagonal cell (with nominal spacing sufficient to avoidcontacting during thermal expansion and contraction during use), forexample as shown in FIGS. 16 and 17.

In addition, the main body 12 of typical embodiments further includesone or more reinforcement segments 28 extending into one or more of thefour openings 22. In the depicted embodiment, for example, the main body12 includes four reinforcement segments 28 with each one extending intoa respective one of the four openings 22 so that each of the fouropenings 22 has a respective reinforcement segment 28 extending into it.In example embodiments, the reinforcement segments 28 each are generallylinear and have a length of about 10 mm to about 20 mm (e.g., 15 mm),though they can be provided in other regular or irregular shapes, sizes,and/or configurations, as may be desired for an application. Thereinforcement segments 28 are thus in addition to the symmetricalsemi-hex arrangement of the two branch segments 18 and the two extensionsegments 24 at each end of the anchor, and do not define any portion ofthe semi-hex openings 22. The reinforcement segments 28 provideadditional contact surface area for engaging and securing the refractoryin place, and they protrude into the unenclosed cell openings 22 toreduce the unobstructed distance across the openings 22, thereby bettersecuring the refractory in the cells and helping reduce the likelyincidence of biscuiting of the refractory.

The reinforcement segments 28 are each typically non-perpendicularlyangled from the branch segment 18 they extend from and non-parallel tothe adjacent branch segment 18 (on the same end of the same anchor 10,with these two branch segments together forming one Y-shaped end of themain body 12) so that they extend into the respective openings 22 in anon-symmetrical manner. The non-perpendicular arrangement of thereinforcement segments 28 can be implemented, for example, by thereinforcement segments 28 being oriented/arranged at about 75 degreesrelative to the branch segment 18 they extend from, and thus at an angleϕ of about 45 degrees relative to the central segment 16 (see FIG. 4).This non-perpendicular arrangement of the reinforcement segments 28avoids right angles in an effort to decrease the likelihood ofbiscuiting and at the same time it forms “pinch” or “catch” surfacesthat help retain the refractory material in the openings 22.

Furthermore, when the anchors 10 are installed into a symmetricallyarrayed system forming generally hexagonal cells 250, for example theanchor system 210 of FIG. 13, this non-perpendicular arrangement of thereinforcement segments 28 results in the reinforcement segments 28 ofadjacent anchors 10 being parallel but not in linear alignment. Thisavoidance of adjacent-anchor reinforcement segments 28 being linearlyarranged thereby avoids creating linear seams in the refractorymaterial, which linear seams can over time form cracking zones where therefractory material tends to fail.

In addition, the main body 12 includes voids 30 that provide additionalcontact surface area (the void-defining exposed through-surfaces 32 ofthe respective main-body segments) for engaging and securing therefractory in place. In this way, the reinforcement segments 28 and thevoid through-surfaces 32 provide better retention/anchoring of therefractory material (more contact surface area), and the voids 30provide for interlinking of the refractory material (which typically isflowable during installation through the voids into and extendingbetween adjacent cells) so it is not isolated into individual cells, toprovide even better retention/anchoring of the refractory material andfurther avoid biscuiting.

In one-piece cast embodiments, the reinforcement segments 28 and thevoids 30 can have the same configuration (size and shape, thoughpositive/solid and negative/void), as depicted, or they can have similaror different configurations if desired. In other one-piece embodiments,the reinforcement segments can be formed by portions of the main bodythat are angled from the adjacent/remainder portions of the main body toleave behind the voids in the main body that typically havesubstantially the same configuration as the respective reinforcementsegment that vacated that void. And in other embodiments, thereinforcement segments are separate pieces attached to the main body,with or without inclusion of the voids.

In addition, the voids 30 typically each extend continuously throughadjacent ones of the branch segments 18 and the extension segments 24that are angled relative to each other, with the lateralthrough-surfaces 32 of the respective main-body segments 32 (whichperipherally define the voids 30) thus extending continuously throughthe adjacent branch and extension segments 18 and 24 and thus having twoangled portions, for the refractory to flow through during installationto interconnect adjacent cells and to provide more surface-areaengagement for further-enhanced securement of the refractory in place.In other embodiments, the voids extend continuously through the centraland branch segments, or continuously through the central, branch, andextension segments.

Furthermore, the main body 12 typically defines underbody gaps 36between the bottom 31 of the main body 12 (e.g., at least a portion ofthe central segment 16 and typically also a portion of the branchsegments 18) and the vessel shell (when at least portions of the bottomsof the extension segments 24 are positioned substantially flush againstthe vessel shell, including direct contact and immediately adjacent suchas within about 0.2 mm). For example, the bottom side (surface or edge)31 of the main body 12 can include an elevated portion 33 (spaced fromthe vessel shell) at a laterally inner portion of the main body (e.g.,at least a portion of the central segment 16), a base portion 35 (flushagainst the vessel shell) at a laterally outer portion of the main body(e.g., at least a portion of the extension segments 24), and atransition portion 34 between and connecting them (e.g., ramped (e.g.,linear or curved) along at least a portion of the branch segments 18 andramped upward toward the central segment) to form the resultingunderbody gaps 36, for instance as shown in FIGS. 4-5. These underbodygaps 36 allow the refractory to flow (during installation) under thecentral segments 16 of the anchor 10 (and typically under portions ofthe branch segments 18) to interlink the refractory material (aftercuring) in the opposite side cells 22 (and also typically in theopposite end cells 22) so it is not isolated in any individual cell toprovide even better retention/anchoring of the refractory material andfurther avoid biscuiting.

In the depicted embodiment, the main body 12 has a substantially level(e.g., planar or irregular) top side (surface or edge), with the centralsegment 16 (or at least a portion of it) having a height dimension H_(C)that is smaller than a height dimension H_(E) of the extension segments24 (or at least a portion of them), so that the underbody gaps 36 areformed under the central segment 16 but not under the extension segments24. As examples, the central segment 16 height H_(C) can be about 15 mmto about 20 mm (e.g., about 17 mm) and the extension segments 24 heightH_(E) can be about 20 mm to about 25 mm (e.g., about 23 mm), with theunderbody gaps 36 typically having a height HG of about 4 mm to about 6mm (and thus with the thin-layer refractory material typically having athickness/height of about 20 mm to about 25 mm. Also, with the undersidegaps 36 being laterally centrally/inwardly located, the more outwardlylocated extension segments 24 (or at least portions of them) contact thevessel shell, which provides a laterally wide footprint or support basefor stability of the anchor 10 in its mounting position. In otherembodiments, the bottom surface of the main body is scalloped, notched,or otherwise shaped to define the underbody gaps.

Each bottom ramped transition 34 runs from a laterally inner location 34a and outwardly (away from the central segment 16) to a laterally outerlocation 34 b. The inner locations 34 a can be for example at (asdepicted) or near where the branch segments 16 angle from the centralsegment 16 (i.e., the opposite laterally outer ends 20 of the centralsegment 16). And the outer locations 34 b of the bottom rampedtransitions 34 can be for example at or near (as depicted) where theextension segments 24 angle from the respective branch segments 18(i.e., the opposite laterally outer ends 26 of the branch segments 18).As shown in FIGS. 4-5, the outer/end locations 34 b of the bottom rampedtransitions 34 can be on the branch segments 16, laterally inward of theextension segments 24, so that there is relatively little/nominallateral overlap between the underbody gaps 36 and the body voids 30(which typically extend through the extension segments 24 and the branchsegments 18). For example, at least a portion of the end location 34 bof the bottom ramped transition 34 can be substantially vertically(axially) aligned with (or slightly laterally inward from, toward thecentral segment 16) the inner edges 32 a of the void-definingthrough-surfaces 32, as best shown in FIGS. 4 and 6. This arrangementprovides a good underflow area (formed by the laterally inward underbodygaps 36) and a good through-flow area (formed by the laterally outwardbody voids 306) for the refractory (during installation) withoutsacrificing the structural integrity of the main body 12 (specifically,the extension segments 24 and the branch segments 18 where the voids 30are located), for better refractory flow-through and retention in theanchor-formed cells.

In this embodiment, this arrangement provides at least one flowpassageway from the central segment 16, along the entire length of therespective branch segments 18, and to the respective extension segments24, extending around the bend between the central and branch segments 16and 18 and around the bend between the branch and extension segments 18and 24, because the flow-through passageways (through the body 12 viathe voids 30) and the flow-under passageways (under the body 12 via thegaps 36) at least nominally laterally overlap (including their endsbeing vertically aligned, for example adjoining and in alignment withthe attached end of the respective reinforcement segment 28). In otherembodiments, the body voids and the under-body gaps do not laterallyoverlap but they nevertheless extend between the central and branchsegments, between the branch and extension segments, and along themajority of the length of these three anchor segments for betterrefractory flow-through and retention in the anchor-formed cells, forexample continuously except where interrupted by the presence ofreinforcement segments 28.

Turning now to the mounting element or feature 14, it is designed formounting the anchor 10 to the thermal vessel (not shown) to beprotected. In the depicted embodiment, and referring particularly toFIG. 5A, the mounting feature 14 is designed for conventionalstud-welding installation methods and equipment, and it thus includes astud (e.g., a cylinder) 38 defining a recess (e.g., a semi-spherical taphole) 40 for receiving a metal interface/pilot element (e.g., a solidball) 39. The interface/pilot element 39 is made of a different material(relative to the stud 38) that has a lower melting point so that itmelts before the stud 38 for optimal stud-welding. For example, theanchor 10 can be made of steel and the interface/pilot ball can be madeof aluminum. Because of this, the interface/pilot element 39 is aseparate component (relative to the stud 38 and to the rest of theanchor 10) in one-piece anchor embodiments.

The stud 38 and the interface/pilot element 39 can have a configurationof a conventional type as is suitable for conventional one-stepstud-welding techniques, so additional details are not provided forbrevity. And the mounting feature 14 can typically include a single stud38 positioned at the center of the central segment 16 of the main body12, with no other attachment of the anchor to the vessel shell (theextension segments 24 typically contact the vessel shell for stabilitywithout being attached), so that vessel expansion and contraction doesnot stress the weld and weaken it. It will be understood that althoughthe stud 38 extends below the main-body extension segments 42 in FIGS.5-6, during stud-welding installation of the anchor 10, the bottom ofthe stud 38 is quickly heated and melted into a molten pool so that,upon completion of the installation, the bottoms of the extensionsegments 42 are immediately adjacent (i.e., contacting or within afraction of a millimeter of contacting) the vessel shell. Also, theextra length of the stud 38, the bevel at the free end of the stud 38,and the interface/pilot element 39 being diametrically centered on thefree end of the stud 38, ensure that, during stud-welding installation,the arc opens to the stud 38 (and not to the anchor main body 12) toquickly heat and melt the interface/pilot element 39, and then the stud38 quickly heats further and melts evenly. In other embodiments,mounting feature is configured for manual welding or other conventionalanchor attachment methods known in the art.

Turning now to the construction of the anchor 10, in typical embodimentsthe main body 12 and the welding stud 38 are made of a single componentpiece of a material, such as a metal alloy (e.g., carbon steel orstainless steel such a 300 or 600 series) with a substantially uniformthickness (e.g., about 2.5 mm), that is sand-cast (or otherwisefabricated by single-use molds) into a one-piece part. Because theanchor 10 is a single piece, no clinching mechanisms are needed tofasten multiple parts together, thereby eliminating a point of failureand simplifying manufacture. Also, because of the one-piececonstruction, the anchors 10 are modular and individually installed sothat the effects of vessel expansion and contraction are minimized tohelp reduce the risk of biscuiting. In other embodiments, the anchor canbe made of other materials and in multiple parts assembled together, orby other fabrication techniques such as other types of casting orforging, as may be desired.

Referring now to FIGS. 7-12, there is shown a thin-layerabrasion-resistant refractory anchoring device 110 according to a secondexample embodiment of the invention. The anchor 110 is a half-unitversion (of the full-unit anchor 10 described above) for installation atthe ends/edges of the surface area of the vessel shell that is to beprotected (as described below) so that areas too small for a full-unitanchor 10 can still be protected without cutting and trimming an anchordown to size. As such, the anchor 110 includes a main body 112 and amounting feature 114 for mounting to the thermal vessel to be protected.The mounting feature 114 can be of the same design as that of the firstembodiment, and the main body 112 can be of the same design as the firstembodiment except as detailed below.

In this half-unit design, the main body 112 includes a central segment116, two branch segments 118 extending from the central segment 116(e.g., at spaced apart locations), two oppositely arranged extensionsegments 124 extending from the respective branch segments 118, and tworeinforcement segments 128 (e.g., formed from adjacent branch andextension segments 118 and 124). The central segment 116, branchsegments 118, extension segments 124, and reinforcement segments 128 canbe of the same design as those of the first embodiment, except that eachend of the main body 112 has only one (instead of two) of the branch,extension, and reinforcement segments 118, 124, and 128. The rampedtransition 134 and other common features are typically also embodied inthe anchor 110. Additional details of the anchor 110 can be included, aswill be understood by persons of ordinary skill in the art, but they arenot repeated for brevity and clarity.

In another aspect, the invention relates to systems of plural thin-layerabrasion-resistant refractory anchoring devices. The systems include anumber of refractory anchors having unenclosed semi-polygonal cellopenings, for example the full-unit anchors 10, the half-unit anchors110, and/or any of the other anchors 10 a-e disclosed herein, and insome embodiments can additionally or alternatively include otherrefractory anchors having unenclosed cell openings in semi-hexagonal orother semi-polygonal shapes. In the depicted embodiments, the refractoryanchoring devices are arranged in the refractory anchoring systems sothat the unenclosed semi-hexagonal cell openings of adjacent ones of theanchoring devices cooperate to form substantially hexagonal cells(including regular hexagonal shapes and oblong ones) for retaining therefractory. In other embodiments, such refractory anchors can bearranged into systems to form cells having other polygonal shapes forretaining the refractory. Examples of such anchoring systems are shownin the figures described below, which are representative for explanatorypurposes only and really only show portions of such anchoring systemsand vessels, which are typically much larger and form an enclosuredefining the thermal-process environment to be protected.

FIGS. 13 and 13A show a first system 210 of the full-unit anchors 10mounted to a vessel shell 2 in a first arrangement and ready forapplication of the refractory 4. In this system 210, the anchors 10 arearranged in an ordered array of rows and columns to cooperatively definean ordered array of generally hexagonal cells 250 in a tessellatedpattern. Each of the generally hexagonal cells 250 is formed by twoadjacent ones of the semi-hexagonal openings 22 of adjacent anchors 10,with each of the cells 250 having all six hexagonal sides formed atleast in part by a segment (central 16, branch 18, or extension 24) ofone of the anchors 10. As depicted, there are spaces between theadjacent anchors 10 (so the cells 250 are not completely bounded or“closed,” and are thus at least partially open), however, at least fourof the six hexagonal cell sides are formed in their entirely by one ofthe anchor segments, and no more than two are not, with those twohexagonal cell non-contiguous (i.e., open) sides having the majority oftheir lengths formed by two adjacent anchor extension segments and theanchor spacings providing flow passageways between adjacent cells 250for the refractory 4 to flow (during installation) and interlink theadjacent cells (after curing, for use).

The central segments 16 of each of the anchors 10 in each column are insubstantial alignment, with the free ends/edges 25 of the extensionsegments 24 of adjacent anchors 10 in substantial alignment but spacedapart, so that the end openings 22 of adjacent anchors 10 in the samecolumn together define one of the cells 250. The spacing between theadjacent extension-segment free ends/edges 25 in each column isfar/large enough to ensure no physical contact during thermal expansionand contraction during high-temperature use and further to provide apassageway for refractory to flow during installation to interlink therefractory in adjacent end-formed cells, but typically close/smallenough to maintain good surface contact between the anchors and therefractory by minimizing spaces in the cells free of any part of theanchors and further to keep the end-formed cells generally hexagonal.For example, the spacing between the extension segment ends/edges 25 istypically less than (or about the same as) the length of each of theextension segments 24 (e.g., about 5 mm to about 10 mm) but long enoughthat the end-formed cells 250 are slightly oblong in their generallyhexagonal shape, as depicted. Without regard to forming substantiallyhexagonal-shaped cells 250, and based simply on industry standards, thespacing is usually about 2 mm to about 20 mm, typically about 10 mm toabout 15 mm, and most typically about 15 mm.

And the central segments 16 of each of the anchors 10 in each row are ina side-by-side parallel alignment, with the extension segments 24 ofadjacent anchors 10 in a side-by-side parallel alignment but spacedapart, so that the central/side openings 22 of adjacent anchors 10 inthe same row together define one of the central-formed cells 250. Thespacing between the adjacent parallel extension segments 24 in each rowis far/large enough to ensure no physical contact during thermalexpansion and contraction during high-temperature use and further toprovide a passageway for refractory to flow during installation tointerlink the refractory in adjacent central-formed cells, but typicallyclose/small enough to maintain good surface contact between the anchorsand the refractory by minimizing spaces in the cells free of any part ofthe anchors and further to keep the central-formed cells generallyhexagonal. For example, the spacing between the adjacent parallelextension segments 24 in each row is typically about the same as thespacing between the adjacent extension-segment ends/edges 25 in eachcolumn such that the central-formed cells 250 are slightly oblong intheir generally hexagonal shape, as depicted. Without regard to formingsubstantially hexagonal-shaped cells 250, and based simply on industrystandards, the spacing is usually about 2 mm to about 20 mm, typicallyabout 10 mm to about 15 mm, and most typically about 15 mm.

The result is an array of generally hexagonal refractory-holding cellsthat is installed without any time-consuming and/or difficult rolling orfitting steps required. Also, the risk of biscuiting is reduced becausethe individual anchors 10 are each individually mounted to the vesselshell 2 and spaced apart sufficiently that the thermal-stress effects ofvessel expansion and contraction are minimized. Further, less metalanchor material is used (e.g., relative to HEXMESH systems), for examplebecause the anchors 10 are spaced apart in each column and in each row,and also by including optional features such as the body voids (e.g.,flow-through passageways) and/or the underbody gaps (e.g., flow-underpassageways). At the same time, though, a more robustanchor-and-refractory protective barrier system is achieved, for examplebecause of the resulting six-sided hex cells, and also by includingoptional features such as the reinforcements (e.g., two in eachresulting hex cell), the body voids (e.g., where the reinforcementsvacated), and/or the underbody gaps (e.g., under the central segments).This helps extend the life of the anchor-and-refractory system, becausethe refractory protects the metal anchors from chemical attack, so lessmetal material means less opportunities/locations for potentialfailures. In this way, the flow passageways between adjacent semi-hexcells of adjacent anchors, including the body voids, the underbody gaps,and the adjacent-anchor spacings, provide the benefits of interlinkedrefractory for better holding/retention and of less metal used for lesscoking/failure.

In addition, because of the column-to-column spacing, and the row-to-rowspacing, between the extension segments 24 of adjacent anchors 10, theresulting generally hexagonal cells 250 are not perfectly hexagonal butinstead are slightly oblong (e.g., irregular or non-equilateral). (Thecells 250 of this embodiment are generally hexagonal for familiarity tocustomers, but it is not necessary for the cells to be perfectly or evengenerally (including oblong) hexagonal in shape.) As depicted, forexample, the generally hexagonal cells 250 formed by adjacent centralopenings are oblong/elongate and oriented at 90 degrees from thegenerally hexagonal oblong/elongate cells 250 formed by adjacent endopenings (i.e., each oblong/elongate central-formed cell 250 is rotatedby 90 degrees relative to the four adjacent oblong/elongate end-formedcells). In other embodiments, the extension segments are shorter thanthe central and branch segments so that even with the end-to-end spacingof adjacent anchors the resulting cells form regular/equilateralhexagons, for example as shown in FIG. 15.

FIG. 14 shows a second system 310 of the full-unit anchors 10 and thehalf-unit anchors 110 mounted to a vessel shell 2 in a secondarrangement and ready for application of the refractory. This secondsystem 310 is similar to the first system 210, with the anchors 10arranged in an ordered array to cooperatively define at least somesubstantially hexagonal cells 350 in a tessellated pattern, except asnoted herein.

In particular, in this system 310, alternating columns of the anchors 10are shifted or offset so that the central segments 16 of adjacentanchors 10 in adjacent columns do not align (in embodiments with a90-degree-rotated anchor orientation, the rows are shifted/offset).Instead, the free/outer ends 25 of two extension segments 18 of adjacentanchors 10 in the same column are received in (or at the edge of) theend opening 22 of an adjacent anchor 10 in an adjacent column. Forexample, the free/outer edges 25 of the extension segments 18 of theanchors 10 in two adjacent columns can all be in an offset alignmentwith each other, as indicated by the vertical broken line in FIG. 14.Also, because of the presence of the reinforcement segments 24 in eachof the end openings 22, the shift or offset can be less than one-half ofan anchor, so that the central segment 16 of one anchor 10 is alignedwith an extension segment 18 of an anchor in the adjacent column(instead of being centered between extension segments 18 of adjacentanchors 10 in the adjacent column), as indicated by the horizontalbroken lines in FIG. 14. This eliminates the anchor extension segments24 in each column being in alignment, as it can be desirable to avoidlinearly arranged anchor segments that could contribute to formation ofseams in the refractory that could be more prone to cracking andfailing.

Furthermore, the system 310 additionally includes a number of thehalf-unit anchors 110 positioned at edges of the vessel surface 2 to beprotected. These anchors 100 are well-suited for use to fill a marginthat is too small for the full-size anchors 10, for example thehalf-unit anchors 110 can be oriented at 90 degrees relative to thefull-size anchors 10 and arranged in a column, for example as shown inthe right margin of FIG. 14. Also, the half-unit anchors 110 can bepositioned at the ends of the columns of full-size anchors 10 that areoffset or shifted, for example as shown at the top and bottom of thecenter column of full-unit anchors 10 of FIG. 14.

FIG. 15 shows a third system 410 of the anchors 10 and modified anchors10 a of a third example embodiment mounted to a vessel shell in a thirdarrangement and ready for application of the refractory. This thirdsystem 410 is substantially similar to the first system 210, with theanchors 10 and 10 a arranged in an ordered array to cooperatively definesome or all substantially hexagonal cells 450 in a tessellated pattern,except as noted herein.

In this system 410, the modified anchors 10 a do not include theextension segments (which are included in the full units 10) extendingfrom their branch segments 18 a, and the anchors 10 and 10 a are arrayedin an alternating fashion with a column of modified anchors 10 a betweencolumns of anchors 10. This system 410 provides substantially the samearrangement as the first system 210, except with fewer extensionsegments, though at the expense of having two different anchorsdesigns/parts to complete the anchoring system 410.

FIG. 16 shows a fourth system 510 of modified/alternative anchors 10 bof a fourth example embodiment mounted to a vessel shell in a fourtharrangement and ready for application of the refractory. This fourthsystem 510 is substantially similar to the third system 410, with theanchors 10 b arranged in an ordered array to cooperatively define someor all substantially hexagonal cells 550 in a tessellated pattern,except as noted herein.

In this system 510, the modified anchors 10 b include the extensionsegments 24 b on two diagonally opposite (cater-corner) branch segments18 b and do not include the extension segments on the other twodiagonally opposite branch segments 18 b. This system 510 providessubstantially the same arrangement as the third system 410, except withonly one anchor design/part needed to complete the anchoring system 510.

FIG. 17 shows a fifth system 610 of modified/alternative anchors 10 c ofa fifth example embodiment mounted to a vessel shell in a fiftharrangement and ready for application of the refractory. This fifthsystem 610 is substantially similar to the fourth system 510, with theanchors 10 c arranged in an ordered array to cooperatively define someor all substantially hexagonal cells 650 in a tessellated pattern,except as noted herein.

In this system 610, the modified anchors 10 c include the extensionsegments 24 c on two diagonally opposite (cater-corner) branch segments18 c and do not include the extension segments on the other twodiagonally opposite branch segments, as in the fourth system 510, andfurther the branch segments 18 c without extension segments are shorterthan those with them, so the extension segments of adjacent anchors 10 ccan be aligned in the manner depicted. This system 610 providessubstantially the same arrangement as the fourth system 510, except withthe anchors 10 c arranged to form a regular hexagonal shape.

FIGS. 18-19 show a portion of a modified/alternative anchor 10 d of asixth example embodiment. The anchor 10 d is substantially similar tothose of the previously described embodiments, except as noted herein.

In this anchor 10 d, the body includes voids 30 d extending continuouslythrough the central segment 16 d and the branch segments 18 d, inaddition to the voids extending continuously through the branch segments18 d and the extension segments 24 d, and the underbody gaps (at thebottom of the central and branch segments) are eliminated (as depicted)or reduced/minimized. As such, the anchor 10 d has refractory flowpassageways extending through and along the central, branch, andextension segments 16 d, 18 d, and 24 d in a continuous manner exceptwhere the reinforcement segments 28 d interrupt them (and adjoin two ofthe void ends).

FIG. 20 shows a portion of a modified/alternative anchor 10 e of aseventh example embodiment. The anchor 10 e is substantially similar tothat of the sixth embodiment, except as noted herein.

In this anchor 10 e, the body includes voids 30 e extending continuouslythrough and along the central, branch, and extension segments 16 e, 18e, and 24 e, the reinforcement segments 28 e have voids 29 e that atleast partially align and communicate with the body voids 30 e (so thereis not mechanical interference (obstruction or interruption) betweenthem), and the underbody gaps (at the bottom of the central and branchsegments) are eliminated (as depicted) or reduced/minimized. As such,the anchor 10 e has a refractory flow passageway extending through andalong the central, branch, and extension segments 16 e, 18 e, and 24 ein a continuous manner, without interruption by the reinforcementsegments 28 e because of their voids 29 e, which provide an additionalflow passageway for additional refractory flow-through and retention.

In another aspect, the invention relates to a method of protectingthermal vessels with refractory linings by installing systems ofrefractory anchoring devices having unenclosed semi-polygonal openingsto form anchor systems having polygonal cells for retaining therefractory. The method can include installing a number of the full-unitanchors 10, the half-unit anchors 110, and/or any of the other anchors10 a-e disclosed herein having unenclosed semi-hexagonal openings, andin some embodiments can additionally include installing other refractoryanchors having unenclosed openings with other semi-polygonal shapes.

For example, when using the anchors 10, the method includes individuallypositioning each of the anchors 10 relative to the vessel shell andindividually mounting them in place so that the semi-hexagonal openings22 of adjacent anchoring devices 10 cooperate to form an orderedarray/system 210 of generally hexagonal-shaped cells 250. In someembodiments, the refractory anchoring devices 10 include a singlestud-welding stud 38 and the mounting process includes stud-welding theanchor devices 10 in place. The method contributes to providing theadvantages of the anchors and anchor systems as described herein. Therefractory can then be installed into the generally hexagonal cells 250to complete the refractory lining process for the thermal vessel.

It is to be understood that this invention is not limited to thespecific devices, methods, conditions, and/or parameters describedand/or shown herein, and that the terminology used herein is for thepurpose of describing particular embodiments by way of example only.Thus, the terminology is intended to be broadly construed and is notintended to be unnecessarily limiting of the claimed invention. Forexample, as used in the specification including the appended claims, thesingular forms “a,” “an,” and “one” include the plural, the term “or”means “and/or,” and reference to a particular numerical value includesat least that particular value, unless the context clearly dictatesotherwise. In addition, any methods described herein are not intended tobe limited to the specific sequence of steps described but can becarried out in other sequences, unless expressly stated otherwiseherein.

While the invention has been shown and described in exemplary forms, itwill be apparent to those skilled in the art that many modifications,additions, and deletions can be made therein without departing from thespirit and scope of the invention as defined by the following claims.

What is claimed is:
 1. An anchoring device for a refractory material forlining a thermal vessel, the anchoring device comprising: a main bodyhaving the shape of two “Y”s arranged end-to-end and including a centralsegment and four branch segments extending from the central segment witha first pair of the branch segments extending from a first part of thecentral segment and with a second opposite pair of the branch segmentsextending from a second part of the central segment that is spaced apartfrom the first part, wherein the four branch segments are each angledwith respect to the central segment at an obtuse angle to form fourunenclosed cell openings between them including two opposite centralopenings and two opposite end openings, wherein the two opposite centralopenings are each semi-hexagonal in shape, wherein the main body furtherincludes four extension segments with each one extending from arespective one of the four branch segments, wherein the four extensionsegments are each angled relative to their respective branch segments atan obtuse angle to define portions of the two opposite end openings suchthat the two opposite end openings are each semi-hexagonal in shape, andwherein each of the extension segments has a respective free endopposite from its respective branch segment; and a mounting elementadapted to mount the main body to the thermal vessel so that theanchoring device can be mounted to the thermal vessel with its extensionsegment free ends spaced apart from an adjacent anchoring device that isseparately mounted to the thermal vessel.
 2. The anchoring device ofclaim 1, wherein the thermal vessel is of a type used in an oilrefinery, another petrochemical-process facility, a chemical-processfacility, a chemical-manufacturing plant, a cement plant, or anotherindustrial facility for performing an industrial process in ahigh-temperature and caustic environment, and wherein the refractorymaterial includes concrete, plastics, ceramics, another conventionalrefractory, or a combination thereof.
 3. The anchoring device of claim1, wherein the main body further includes four reinforcement segmentswith each one extending into a respective one of the four unenclosedcell openings so that each of the four unenclosed cell openings has arespective reinforcement segment extending into it.
 4. The anchoringdevice of claim 3, wherein each reinforcement segment extends from arespective one of the four branch segments, wherein the reinforcementsegments are in addition to the branch segments and do not define anyportion of the four unenclosed openings.
 5. The anchoring device ofclaim 1, wherein the main body has at least one bottom surface thatdefines a base portion and an elevated portion that is elevated relativeto the base portion to form an underbody gap between the main bodybottom surface and the vessel, wherein the underbody gap allows therefractory to flow under the anchor when the anchor is mounted to thevessel and the refractory is being installed.
 6. The anchoring device ofclaim 5, wherein at least a portion of the base portion is at an outerend of one of the branch segments, at least a portion of the elevatedportion is on the respective central segment, and the bottom surfacefurther includes a transition portion extending between the base andelevated portions.
 7. The anchoring device of claim 1, wherein the mainbody defines at least one void that extends through and along at least aportion of one of the branch segments, and wherein the body void allowsthe refractory to flow through the anchor main body when the anchor ismounted to the vessel and the refractory is being installed.
 8. Theanchoring device of claim 1, wherein the obtuse angle between eachextension segment and the respective branch segment is the same as theobtuse angle between each branch segment and the central segment, sothat the extension segments are parallel to the central segment, and sothat all four of the unenclosed openings have a same semi-hexagonalshape.
 9. The anchoring device of claim 1, wherein each of the branchsegments has a length that is substantially the same as a length of thecentral segment, and each of the extension segments has a length that isabout half the length of the central and branch segments, wherein eachof the four unenclosed cell openings has a same semi-hexagonal area. 10.The anchoring device of claim 1, wherein the main body defines at leastone void that extends through and along at least one of the branchsegments and at least one of the respective extension segments, andwherein the body void allows the refractory to flow through the anchormain body when the anchor is mounted to the vessel and the refractory isbeing installed.
 11. The anchoring device of claim 1, wherein the mainbody has at least one bottom surface that defines a base portion on oneof the extension segments, an elevated portion on the central segmentand elevated relative to the base portion, and a ramped transitionportion on the respective branch segment extending between the base andelevated portions, to form an underbody gap between the main body bottomsurface and the thermal vessel along the central segment and at least aportion of the respective branch segment, wherein the underbody gapallows the refractory to flow under the anchoring device when theanchoring device is mounted to the thermal vessel and the refractory isbeing installed.
 12. The anchoring device of claim 1, wherein the mainbody defines at least one flow passageway through which the refractoryflows when the anchor is mounted to the vessel and the refractory isbeing installed to interconnect the refractory in adjacent of theopenings, wherein the flow passageway comprises at least one body voidformed through the main body, underbody gap formed at a bottom surfaceof the main body, or both.
 13. The anchoring device of claim 1, whereinthe mounting element includes a stud-welding stud defining a recess forreceiving a pilot interface element, wherein the stud extends from thecentral segment of the anchor main body.
 14. The anchoring device ofclaim 1, wherein the main body and the mounting element are made of asingle component piece of a metal material that is formed by castinginto a one-piece part, wherein the anchoring device includes noclinching mechanisms to fasten multiple parts together.
 15. Theanchoring device of claim 14, wherein the main body further includes twoextension segments each extending from a respective one of the fourbranch segments and diagonally opposite each other, wherein theextension segments are each angled relative to their respective branchsegments at an obtuse angle to define portions of the two opposite endopenings such that the two opposite end openings are each semi-hexagonalin shape, and wherein each of the extension segments has a respectivefree end opposite from its respective branch segment.
 16. An anchoringdevice for a refractory material for lining a thermal vessel, theanchoring device comprising: a main body having the shape of two “Y”sarranged end-to-end and including a central segment and four branchsegments extending from the central segment with a first pair of thebranch segments extending from a first part of the central segment andwith a second opposite pair of the branch segments extending from asecond part of the central segment that is spaced apart from the firstpart, wherein the four branch segments are each angled with respect tothe central segment at an obtuse angle to form four unenclosed cellopenings between them including two opposite central openings and twoopposite end openings, wherein the two opposite central openings areeach semi-hexagonal in shape, wherein the main body further includes atleast one extension segment extending from at least one of the fourbranch segments; and a mounting element adapted to mount the main bodyto the thermal vessel, wherein the main body defines at least one voidthat extends through and along the at least one extension segment andthe respective branch segment, and wherein the body void allows therefractory to flow through the anchor main body when the anchor ismounted to the vessel and the refractory is being installed.
 17. Theanchoring device of claim 16, wherein the at least one void comprisesfour body voids with each body void extending through a respective oneof the extension segments and the adjacent branch segment so that thebody voids extend continuously through and along the angles between theextension and branch segments.
 18. An anchoring device for a refractorymaterial for lining a thermal vessel, the anchoring device comprising: amain body having the shape of two “Y”s arranged end-to-end and includinga central segment and four branch segments extending from the centralsegment with a first pair of the branch segments extending from a firstpart of the central segment and with a second opposite pair of thebranch segments extending from a second part of the central segment thatis spaced apart from the first part, wherein the four branch segmentsare each angled with respect to the central segment at an obtuse angleto form four unenclosed cell openings between them including twoopposite central openings and two opposite end openings, wherein the twoopposite central openings are each semi-hexagonal in shape, wherein themain body further includes at least one extension segment extending fromat least one of the four branch segments; and a mounting element adaptedto mount the main body to the thermal vessel, wherein the main body hasat least one bottom surface that defines a base portion on the at leastone extension segment, an elevated portion on the central segment andelevated relative to the base portion, and a ramped transition portionon the respective branch segment extending between the base and elevatedportions, to form an underbody gap between the main body bottom surfaceand the thermal vessel, wherein the underbody gap allows the refractoryto flow under the anchoring device when the anchoring device is mountedto the vessel and the refractory is being installed.
 19. The anchoringdevice of claim 18, wherein the body void and the underbody gaplaterally overlap or ends thereof are in vertical alignment.
 20. Ananchoring device for a refractory material for lining a thermal vessel,the anchoring device comprising: a main body having the shape of two“Y”s arranged end-to-end and including a central segment and four branchsegments extending from the central segment with a first pair of thebranch segments extending from a first part of the central segment andwith a second opposite pair of the branch segments extending from asecond part of the central segment that is spaced apart from the firstpart, wherein the four branch segments are each angled with respect tothe central segment at an obtuse angle to form four unenclosed cellopenings between them including two opposite central openings and twoopposite end openings, and wherein the two opposite central openings areeach semi-hexagonal in shape; and a mounting element adapted to mountthe main body to the thermal vessel, wherein the mounting elementincludes a stud-welding stud that extends from the central segment ofthe anchor main body and defines a recess at a free end opposite fromthe central segment of the anchor main body, wherein the stud recess isconfigured to receive a pilot interface element, and wherein theanchoring device can be mounted to the thermal vessel in a positionspaced apart from an adjacent anchoring device that is separatelymounted to the thermal vessel, wherein the main body and the mountingelement are made of a single component piece of a metal material that isformed by casting into a one-piece part, wherein the anchoring deviceincludes no clinching mechanisms to fasten multiple parts together.